Electrical connector assembly for power distribution system

ABSTRACT

An electrical connector having a housing member formed with a plurality of interior U-shaped channels. A bus member is positioned in each of the channels having a cross-section similar to that of the channels. A plural series of bores are formed through the housing, each defining spaced, electrical contact locations. Electrical contacts of each series are electrically connected at one end to one of the bus members and are positioned in some of the bore. The housing portion which contains the bores is formed with a connector shell extending therefrom, the outer surface of the shell having a polarization key or keyway formed thereon for interconnection with a mating electrical connector.

[ Sept. 10, 1974 ELECTRICAL CONNECTOR ASSEMBLY FOR POWER DISTRIBUTION SYSTEM [75] Inventor: Dennis E. Clarke, Van Nuys, Calif.

[73] Assignee: Lockheed Aircraft Corporation,

Burbank, Calif.

[22] Filed: Sept. 22, 1972 [21] Appl. No.: 292,482

[52] US. Cl. 339/22 B, 339/198 R, 339/242 [51] Int. Cl. .J H01r 13/60 [58] Field of Search 339/198, 19, 22 B, 242, 339/222,18 R, 18 C, 18 P, 210 R, 210 M, 157 R [56] References Cited UNITED STATES PATENTS 1,752,225 3/1930 Birchall 339/157 R X 2,924,808 2/1960 Hewes et al. 339/198 3,233,209 2/1966 Lazar et al..... 339/198 3,273,l08 9/1966 Radocy 339/210 R 3,373,398 3/1968 Volinskie 339/217 Primary Examiner-Bobby R. Gay

Assistant Examiner-Robert A. Hafer Attorney, Agent, or Firm-Billy G. Corber; Lowell G. Turner [5 7] ABSTRACT An electrical connector having a housing member formed with a plurality of interior U-shaped channels. A bus member is positioned in each of the channels having a cross-section similar to that of the channels. A plural series of bores are formed through the housing, each defining spaced, electrical contact locations. Electrical contacts of each series are electrically connected at one end to one of the bus members and are positioned in some of the bore. The housing portion which contains the bores is formed with a connector shell extending therefrom, the outer surface of the shell having a polarization key or keyway formed thereon for interconnection with a mating electrical connector.

11 Claims, 10 Drawing Figures PAIENIEB SEPI 0mm sum 2 or 2 ELECTRICAL CONNECTOR ASSEMBLY FOR POWER DISTRIBUTION SYSTEM FIELD OF THE INVENTION The field of art to which the invention pertains includes electrical connectors for power distribution systems, particularly with respect to a connector system having a housing to which electrical connectors may be rapidly connected under emergency conditions.

BACKGROUND AND SUMMARY OF THE INVENTION Emergency power distribution systems are installed on ships so that when sections of a ships electrical service have been destroyed or temporarily disabled, power to a portion of the ship may be bridged so as to provide electrical power to other portions of the ship. Conventional casualty power distribution systems presently used on board ships extend through the ship bulkhead and deck. Individual cable conductors are connected by means of ferrules inserted into a terminal of a power distribution housing, and are secured with a set screwto make electrical connection to the housing. Typically when the electrical connections are made to the power distribution housing, an emergency situation exists on board the ship. The person making the connections may be working in a dark smoke-filled room and cannot determine to which terminal the cable conductor is to be connected. Under these circumstances cross-phasing or short circuiting of the cable conductor can occur which can damage or destroy equipment. In addition, it is normally necessary under such circumstances to provide power to a plurality of separate locations from the housing.

In order to overcome the attendant disadvantages of prior art power distribution systems, the present invention provides an electrical connector system for rapid connection between an electrical connector to which a plurality of conductors are connected and the power distribution housing. A plurality of the connectors may be secured to the power distribution housing and the danger of cross-phasing or short circuiting is eliminated. The electrical connections may be made rapidly and can be performed with limited light sources.

Specifically, the electrical connector system comprises a housing member having a plurality of generally U-shaped channels formed therein. A plurality of bus members having a cross-section similar to that of the channels are positioned in the respective channels. A plural series of bores are formed through the housing to contain electrical contact members therein which are each electrically connected at one end to one of the bus members. Each bus member interconnects all of the contact locations in a respective series. The housing portion which contains the bores is formed with a connector shell extending from the housing, the outer surface of the shell containing polarizing key or keyway means formed thereon for mating with an electrical connector. Each bus member is formed with a lug positioned to mate with an electrical conductor insertable through a housing bore. The connector shell portion of the housing is provided with spring locking means axially aligned with the electrical contacts in the bores, and mates with a shell member. A cover member is provided to environmentally enclose the connector shell portion and is retained, e.g. with a lanyard, adjacent the housing member when removed.

The advantages of the invention both as to its construction and mode of operation, will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an electrical connector assembly;

FIG. 2 is a plan view, partly in section, of the electrical connector assembly of FIG. 1;

FIG. 3 is a partial top view of the connector assembly of FIG. 2 with the top plate removed;

FIG. 4 is a partial bottom view of the top plate of the connector assembly of FIG. 1;

FIG. 5 is a perspective view of the electrical bus member and contacts utilized in the connector assembly of FIG. 1;

FIG. 6 is a view, partly in section, depicting the electrical contacts in the connector assembly of FIG. 1;

FIG. 7 is a cross-sectional view of the electrical contact of FIG. 6 taken along the line 7-7 thereof;

FIG. 8 is an alternative arrangement of an electrical contact utilized in the connector assembly of FIG. 1;

FIG. 9 is a cross-sectional view of a contact shown in FIG. 8 taken along the line 99 thereof; and

FIG. 10 is an alternative embodiment of the connector assembly depicting a pair of connector assemblies mounted back-to-back.

DETAILED DESCRIPTION Referring now to FIG. I, there is shown a preferred embodiment of the connector housing member 12 constructed in accordance with principles of the invention. The housing member 12 is formed of a first side wall 14 and a second side wall 16 and a bottom wall 18. The housing member is also formed of a front wall 22 and a rear wall opposite the front wall 22,the rear wall 22 being integral with a mounting plate 24. The mounting plate 24 has a plurality of openings 26 therethrough so that the mounting plate 24 can be secured to a wall or bulkhead 28 by means of bolts 32.

Extending downwardly from the bottom surface 18 of the housing is a first plug connector shell 34 having a raised ridge surface 36 which is integrally flush with the front wall 22, and a pair of recessed side portions 38 and 42 which are formed in a plane parallel to the surface 36. The surface 36 and its junction with portions 38 and 42 define a polarizing key for insertion in a keyway 44 formed in a receptacle shell 46 when mated with the plug shell 34. The top surface 52 of the housing 12 has a plate 54 positioned thereon which is secured to the surface 52 by means of screws 56.

A second plug shell 62 and a third plug shell 64 extend outwardly from the side walls 14 and 16, respectively, in a plane parallel to the top surface 52. The plug shell 62 which can be seen in FIG. 1 is configured as the mirror image of the plug shell 64 and contains a recess 65 which is cut into one side thereof which, together with a recess 66 formed in the top plate 54 and the surface of the plug shell 14 flush with the front wall 22, forms a polarizing key for a mating connector shell. The polarizing key in the plug shell 62 is identical in envelope shape to the polarizing key formed by the surfaces 36, 38 and 42 in the plug shell 34 at the bottom of the insulator housing. A mirror imaged polarizing key is formed upon the plug shell 64.

When electrical connections are not made to the plug shells 34, 62 or 64, the plug shells can be covered by means of a protective dust cover housing 66. The cover housing contains an opening which is identical to the opening formed in the receptacle shells so that the plug shells may be completely covered. In addition a pair of spring locking mechanisms shown generally at 70 at opposite ends of the cover 66 provide a rapid means for securing or releasing the covers 66 from the connector housing as will be explained hereinafter. A lanyard 72 may be secured between one of the members 70 and one of the screws 56 used to secure the top plate 54 to the housing 12. Thus, when the cover 66 is removed for replacement with a connector member the cover can be readily retrieved. v

A recess 74 is formed in the top surface of the plate 54. A bore 75 (shown in dotted lines) extends through the top plate 54 within the recess 74, enabling a grommet 76 to be positioned therein, with the top surface of the grommet being flush with the top surface of the top plate 54. The grommet 76 contains a central bore 78 therethrough for enabling electrical conductors to extend into the interior of the housing member 12 when desired.

Referring now to FlGS. 2 and 3, in addition to H6. 1, the interior of the connector housing member 12 is shown in greater detail. At the end of the housing formed integral with the mounting plate 24, an enlarged bore 82 is formed which extends from an interior rear wall 83 through the mounting plate thus enabling electrical conductors such as the conductor 84 to be brought through the bulkhead 28 and into the interior of the connector housing 12.

Three generally U-shaped channels, as viewed as in FIG. 2, are formed in the interior of the housing member 12. These U-shaped channels are defined by the inner front wall surface 87, a pair of partitions 88 and 89, and an interior rear surface 90. Positioned between these surfaces are U-shaped bus members 92. The bus members 92, usually of flattened cross-section, lie flat against the bottom interior surface 94 of the insulator member as well as the side interior wall surfaces 96 and 98. While three U-shaped channels have been shown in order that the insulator member be used with a three wire system, it should be understood that more or less U-shaped channels could be provided depending upon a number of electrical conductors interconnected by the housing of FIGS. 1 through 3.

A series of bores 102 are formed in each of the plug shells 62 and 64 which extend to the top surface of the housing and have a diameter less than the width of the bus members 92. The bus members 92 are positioned in the interior of the housing adjacent to the bores 102. The front end of the bores 102 contain an inwardly facing shoulder 104 which enables contacts 106 to be retained between the shoulder 104 and the bus members 92. Extending outward from the bore 102 is a reduced diameter bore section 108 which ends at a tapered flared opening 112 at the front surface of the plug shells 62 and 64 facilitating insertion of mating contacts as will be explained hereinafter.

In the plug shell 34, a series of bores 114 extend from the bottom surface 94 of the interior of the housing member and are of such diameter that contacts similar to the type used in the plug shells 62 and 64 may be inserted therein. A reduced diameter bore 116 extends forwardly from the bores 114 and a flared surface 118 extends from the front end of the bore 116 to the front exterior surface of the shell 34. Each of the bus members 92 interconnect all of the locations in a respective series of the bores in the plug shells 34, 62 and 64.

To secure the conductors 84 to the bus member 92, a lug 122 is secured to each of the bus members by means of a screw 124 which protrudes through the bus member 92 and into an opening 126 formed in the interior surface of the housing member. The lug 122 may be secured to the conductor 84 by means of a conventional clip positioned in a housing 128 which is normally crimped or soldered to the conductor 84.

Referring now to FIG. 4 the bottom surface of the top plate 54 is shown in greater detail. The bottom surface contains ridge plates 132 formed at either end of the bottom surface and a central ridge section 134 having three fingers 136 extending toward each of the plates 132. Also positioned on the bottom surface is a rubber gasket-like material 138 having a pair of end rails 142 and 144 which are connected by means of side rails 146 extending between the ridge plate 132 and the section 134. Finger-like gasket material 152 extends from the end rails between the three fingers 136.

The ends of the U-shaped bus member 92 extend slightly above the top surface 52 of the housing member 12 as can be clearly seen in FIG. 2. When the top plate 54 is positioned on the top surface 52 of the housing member, the ends of the U-shaped member 92 correctly positions the plate between the ends of the fingers 136 and the side sections 146. The gasket material 152 forms a seal with the partitions 88 and 89; thus, the gasket material 138 forms an environmental seal covering the top surface 52 in the vicinity of the electrical contacts positioned in the bores 102.

Referring now to FIGS. 5 through 8 the electrical contacts used in the connector system are shown in greater detail. These contacts may be of the type depicted in US. Pat. No. 3,064,226. The contacts 106 contain an enlarged cylindrical section 164 which is normally bolted or swaged by means of a bolt or pin 166 to the U-shaped bus members 92. Alternatively, the section 164 may contain a threaded end which extends through the bus members 92 and may be secured thereto by means of a nut as shown in the aforementioned US. Patent. Extending forwardly from the cylindrical section 164 is a generally spherical portion 168 whose outer diameter is less than the cylindrical portion 164 and contains a flattened front surface 172. Al ternatively, the surface 172 need not be flattened and of the spherical portion 168. A split sleeve 174 contains a pair of springs 176 and 178 around the outer circumference thereof. One end of the split sleeve is secured to the spherical portion 168 and the other end of the split sleeve is adapted to be mated with a pin contact contained in the receptacle housing 46. The use of the split sleeve permits some movement of the sleeve in a plane perpendicular to the sleeve axis during the mating process as is explained in greater detail in the aforementioned U.S. Patent. The cylindrical portion 164 and spherical portion 168 together with the split sleeve 174 are all mounted in either the bores 102 of the plug shell 62 or 64 or the bores 114 of the plug shell 34.

the front end thereof may be formed of a continuation Referring now to FIGS. 8 and 9, there is shown an alternative embodiment of a socket contact 182 which may be positioned in the bores 102 and 114. The socket contact contains a conventional split sleeve 184 which enables the socket to expand slightly upon insertion of a conventional pin contact therein providing a good contacting surface therebetween.

Referring once again to FIG. 1 and 6, the receptacle shell 46 contains a ridge 202 on its exterior surface which extends longitudinally thereon. The ridge is adjacent the keyway 44 so as to enable a person to identify the position of the keyway 44 by feel alone when assembling the connectors.

A front interior bore 204 is formed at the front end of the receptacle shell 46 which enables the receptacle shell 46 to be mated to either the plug shell 34 or the plug shells 62 and 64. The bore 204 terminates at a forward facing shoulder 206 formed in the interior of the shell 46.

A plurality of recesses 208 are formed in the shoulder 206 .which extend into the interior of the shell. Positioned in each of the recesses is a pin contact 212 which may be threadably secured therein by means of a nut 214 which engages the threads 216 on the rear surface of the pin contact. The nut 214 abuts a washer 218 which is mounted flush with a forward facing shoulder 222 formed at the rear end of the recess 208. A portion of the contact 212 extends rearwardly to an enlarged section 224 which is positioned in an enlarged rearward facing bore 226 and secured thereto by means of a sleeve 228. Normally, the sleeve 228 is secured to one end of electrical conductors 232. The front end of the pin contact 212 contains a reduced diameter cylindrical section 232 extending forward from the threaded section 216 and terminates at an enlarged spherical section 234 formed at the front end of the section 232 with the section 234 having a flat front surface 236 which is similar to the front surface 172. The section 234 is inserted into the sleeve 174 when the receptacle shell is mated with either the plug shell 34 or the shells 62 or 64.

As can be seen in FIG. 1, the pin contacts 212 are aligned in the bore 204. Flattened head sections 252 are positioned on opposite ends of the three aligned pin contacts 212 and are operable by spring-biased mechanisms 253 similar to the spring-biased mechanism 70 on the cover housing 66. When the connectors are mated, the head sections 252 are inserted into bores 256 formed at the extreme ends of the front surface of the plug shells 34, 62 and 64. The spring biased mechanisms 253 are identical with the mechanism 70 shown in FIG. 2, and will be explained with reference thereto. Positioned within the bores 256 are sleeve members 262 having a reduced width front section 264 and a reduced rear section 266 which is interconnected by means of an enlarged width central section 268. The flattened section 252 is rotatably mounted on a shaft 272 secured to a knob 274. A washer 276 is loosely positioned on the shaft 272 and prevents the front end of the member 252 from being retracted into the interior of the receptacle shell. The knob 274 is spring-biased by means of a spring 282 and is rotated until the portion 252 is polarized with the opening in the sleeve 262. When the section 252 is inserted through the section 264, the knob 274 is rotated until the section 252 is locked in the interior central section 268. Then, the receptacle connector shell 46 is secured to the plug shells. Similarly the covers 66 are secured to the plug shells.

As can be readily seen, the receptacle shells 46 may be rapidly mounted onto any one of the plug shells 36, 62 and 64. It should be understood, of course, that while the system has been described with a power input supplied by means of input power conductors 84 secured to the bussing members 92, any of the receptacle shells 46 can contain the primary input power and the primary input power could be connected to any one of the plug shells. The other two plug shells could then be used as output power connections.

Referring now to FIG. 10 there is shown a pair of insulator housing members 302 and 304 each of which may be similar to the insulator housing member 12 depicted in FIG. 1. The insulator housing members 302 and 304 contain mounting flanges 306 and 308 respectively, which are secured to housing members 312 and 314 respectively, mounted on opposite sides of a bulkhead 316. In such an arrangement the openings 82 in each of the insulator housings may contain electrical conductors which connect together the bus bars in each of the insulator housings 302 and 304. Thereafter, a cable 322 may be inserted into the opening 78 formed in the top plate of one of the insulator housings 302 and 304. In such an arrangement six outputs can be provided between the stacked opposed insulator housings 302 and 304.

It should further be understood that while the U- shaped bus members 92 are shown interconnecting contacts in three sets of plug shells that more or less number of plug shells could be used. Alternatively, the plug shells 36, 62 and 64 could be formed as receptacle shells as well and mated with corresponding plug shells. Moreover, a combination of plug and receptacle shells could be positioned on the insulator housing 12 to be mated with respective receptacle or plug shells.

I claim:

1. An electrical connector comprising:

a housing member having a plurality of spaced, outwardly extending connector shell portions, each said connector shell portion having a series of bores formed therethrough, said bores of each series definingg spaced electrical contact location, an outer surface upon each said connector shell portion having polarizing key means formed thereon:

said housing having a plurality of u-shaped channels formed therein;

a bus member positioned in each of said u-shaped channels, each said bus member interconnecting one of said bores in each of said series, each said bus member connecting at least three noncollinear bores; and

electrical contact members positioned in at least some of said bores, each being electrically connected at one each to one of said bus members.

2. An electrical connector in accordance with claim 1 wherein the bores comprising each series of said plural series of bores are parallel with respect to each other.

3. An electrical connector in accordance with claim 1 wherein said bus members include flattened crosssections for nesting within said U-shaped channels.

4. An electrical connector in accordance with claim I wherein said bus members have a lug positioned v means being aligned with said electrical contact members in said bores, said spring lockingmeans being ma table with a connector shell portion.

" 3 wherein three mateable connector shell portions ex- 6. An electrical connector in accordance with claim 5 including a cover member for environmentally enclosing said mateable connector shell portion.

7. An electrical connector in accordance with claim 6 wherein said cover member contains meansfor retaining said cover member adjacent said housing mem her when said cover member is removed from said" mateable connector shell portion. I

8. An electrical connector in accordance'with claim 5 wherein said connector shell portion comprises an tend from said housing, each of said mateable connector shell portions being adjacent one of the legs of each of said U-shaped channels with electrical contact members in one of said series of bores being positioned in each of said mateable connector shell portions.

10. An electrical connector in accordance with claim 9 wherein each of said U-shaped channels is defined by a central portion and a pair of side portions, one of said mateable connector shell portions being adjacent to the center of said centralportion, the other of said mateable connector shell portions being adjacent to a free ffendof onefof the side portions, respectively, and wherein-:each of said connector shell portions extend awavfr'orn said'housing in a plane perpendicular to its respective adjacent channel portion.

. lllAn' electrical connector in accordance with claim "1 and further comprising means for facilitating mating electrical connector member having contacts. therein for electrically interconnecting electrical conductors to said bus members.

9.,An electricalfconnector in accordance with claim of said electrical contacts with the contacts of a mating electrical connectonwhensaid'mating contacts are not in exact alignment.,-. 

1. An electrical connector comprising: a housing member having a plurality of spaced, outwardly extending connector shell portions, each said connector shell portion having a series of bores formed therethrough, said bores of each series definingg spaced electrical contact location, an outer surface upon each said connector shell portion having polarizing key means formed thereon: said housing having a plurality of u-shaped channels formed therein; a bus member positioned in each of said u-shaped channels, each said bus member interconnecting one of said bores in each of said series, each said bus member connecting at least three noncollinear bores; and electrical contact members positioned in at least some of said bores, each being electrically connected at one each to one of said bus members.
 2. An electrical connector in accordance with claim 1 wherein the bores comprising each series of said plural series of bores are parallel with respect to each other.
 3. An electrical connector in accordance with claim 1 wherein said bus members include flattened cross-sections for nesting within said U-shaped channels.
 4. An electrical connector in accordance with claim 1 wherein said bus members have a lug positioned thereon for mating with an electrical conductor insertable through a bore in said housing.
 5. An electrical connector in accordance with claim 3 wherein said mating connector shell portion of said housing contains locking means therein, said locking means being aligned with said electrical contact members in said bores, said spring locking means being matable with a connector shell portion.
 6. An electrical connector in accordance with claim 5 including a cover member for environmentally enclosing said mateable connector shell portion.
 7. An electrical connector in accordance with claim 6 wherein said cover member contains means for retaining said cover member adjacent said housing member when said cover member is removed from said mateable connector shell portion.
 8. An electrical connector in accordance with claim 5 wherein said connector shell portion comprises an electrical connector member having contacts therein for electrically interconnecting electrical conductors to said bus members.
 9. An electrical connector in accordance with claim 3 wherein three mateable connector shell portions extend from said housing, each of said mateable connector shell portions being adjacent one of the legs of each of said U-shaped channels with electrical contact members in one of said series of bores being positioned in each of said mateable connector shell portions.
 10. An electrical connector in accordance with claim 9 wherein each of said U-shaped channels is defined by a central portion and a pair of side portions, one of said mateable connector shell portions being adjacent to the center of said central portion, the other of said mateable connector shell portions being adjacent to a free end of one of the side portions, respectively, and wherein each of said connector shell portions extend away from said housing in a plane perpendicular to its respective adjacent channel portion.
 11. An electrical connector in accordance with claim 1 and further comprising means for facilitating mating of said electrical contacts with the contacts of a mating electrical connector when said mating contacts are not in exact alignment. 